Electrode diameter sensing consumables

ABSTRACT

The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch, and a sensor, in which the sensor is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor. The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

BACKGROUND

The invention relates generally to welding systems, including weldersand welding torches. Specifically, the present disclosure relates tosystems and methods for detecting the diameter of a welding materialused in a welding operation and automatically setting appropriatewelding parameters.

Welding systems have become virtually ubiquitous throughout industry.Such systems are currently used in all industries, includingmanufacturing, physical plant construction, shipbuilding, pipelineconstruction, maintenance and repair, and so forth. Many weldingapplications may be complex projects that often require different typesof welds to be made, including welds of different sizes. Such weldsoften require the use of welding material of different sizes. Forexample, a fine weldment may require the use of a relatively thinwelding wire and a large, robust weldment may require the use of arelatively thick welding wire. In order to complete such a project,welding material of one size may need to be swapped out for a weldingmaterial of a different size. This may occur one of more times during asingle welding operation or session. Generally, an operator must stopwelding and manually change the welding material.

Additionally, for best performance, welding material of a certain sizegenerally requires a specific set of welding parameters such as arcstarting parameters. Amperage level is an example. As such, when weldingmaterial is changed, the operator generally must return to the welder tomanually change and/or set one or more of these parameters.Unfortunately, this creates a higher probability of operator error formany reasons. For example, an operator may not be aware that arcstarting parameters should be changed when changing the weldingmaterial, and even a user who is aware may forget to do so. It may alsobe the case that the user does change the arc starting parameters, butchanges them to an incorrect setting. This may result in a decrease inproductivity, as well as in poor weld quality. Accordingly, there existsa need for improved welding systems that overcome such drawbacks.

BRIEF DESCRIPTION

In an exemplary embodiment, a welding system includes a welding torch, awelder coupled to the welding torch configured to produce a welding arcin the welding torch, and a sensor configured to sense a parameterindicative of a size of a welding material used by the welding torch.The sensor is configured to send a signal to the welder, the signalrepresenting the parameter indicative of the size of the weldingmaterial. The welder is configured to automatically implement at leastone of an arc starting parameter or a welding parameter based on thesignal.

In another embodiment, a welding system includes a welding torchincluding a sensor configured to sense a parameter indicative of a sizeof a welding material used by the welding torch and to output a signalrepresentative of the sensed parameter, and a controller disposed withina welder. The controller is configured to receive the signal from thesensor, to convert the signal into a corresponding set of arc startingparameters or welding parameters, and to implement the arc startingparameters or welding parameters.

In another embodiment, a method includes the steps of determining asensor signal using a sensor associated with a welding torch, in whichthe sensor signal is indicative of a size of a welding material used bythe welding torch, communicating the sensor signal from the sensor to acontroller disposed within a welder, processing the sensor signal bytranslating the sensor signal into a corresponding set of arc startingparameters or welding parameters, and implementing the corresponding setof arc starting parameters or welding parameters in the welder, in whichthe welder is configured to produce an arc with the corresponding set ofarc starting parameters or welding parameters.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is an exploded view of a GTAW welding torch, in accordance withembodiments of the present disclosure;

FIG. 2A is a view of a collet and collet body assembly, in accordancewith embodiments of the present disclosure;

FIG. 2B is a view of an alternate collet and collet body assembly, inaccordance with embodiments of the present disclosure;

FIG. 3 is an exploded view of a GMAW welding torch, in accordance withembodiments of the present disclosure;

FIG. 4 is a cross-sectional view of an assembled nozzle, diffuser, andcontact tip of a SMAW welding torch, in accordance with embodiments ofthe present disclosure;

FIG. 5 is a side view of an electrode holder to be used with an SMAWwelding system, in accordance with embodiments of the presentdisclosure;

FIG. 6 is a flow chart illustrating the process of automaticallyimplementing arc starting parameters, in accordance with embodiments ofthe present disclosure; and

FIG. 7 is a welding system that includes a material sensing and controlsystem, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

As described in greater detail below, provided herein are embodiments ofwelding systems including material sensing and control systems adaptedto provide an indication of the size of a welding material in a weldingdevice (e.g., a welding torch, an electrode holder, and so forth) inorder to automatically change and/or set welding parameters such as arcstarting parameters suited for the particular welding material size. Forexample, in one embodiment, the material sensing system may sense when awelding wire of size A has been replaced by a welding wire of size B ina welding torch, and the control system may automatically adjust one ormore arc starting parameters accordingly upon detection of the new sizeof welding wire. For further example, in such an embodiment, the controlsystem may alter an amperage setting of a welder to produce less heat,as welding wire of size B may perform better at a lower temperaturecompared to welding wire of size A. Similarly, in some embodiments, theamperage may be increased or decreased, or other parameters may bealtered in a suitable manner to provide ideal welding parameters for aspecific welding material size.

The automated selection and implementation of appropriate arc startingparameters frees an operator from having to manually set the correct arcstarting parameters when changing welding material sizes. As such, thewelding system presented herein lowers the potential of having incorrectarc starting parameters when welding material is changed, as the correctarc starting parameters are determined and set automatically.Additionally, the welding system presented herein may also be configuredto automatically set, maintain, and adjust other operating or weldingparameters during welding. The disclosed welding system may be used withmany types of welding methods and equipment, including gas tungsten arcwelding (GTAW) welding, gas metal arc welding (GMAW) welding, shieldingmetal arc welding (SMAW) welding, and so forth. For brevity andillustrative purposes, only a sample of the embodiments of the disclosedwelding system is included in the present disclosure.

Turning now to the figures, FIG. 1 is an exploded view of a GTAW weldingtorch 10 that may be used in a welding system, such as the weldingsystem 76 illustrated in FIG. 7. It should be noted that the GTAWwelding torch 10 illustrated in FIG. 1 is but one exemplary type ofwelding torch that may utilize the material sensing techniques describedherein. For example, additional exemplary welding torches that mayutilize the present techniques are illustrated in FIGS. 3 and 5. In theembodiment illustrated in FIG. 1, the GTAW welding torch 10 includes anelectrode 12, a cup 14, a collet body 16, a collet 18, a heat shield 20,a torch body 22, a back cap insulator 24, an o-ring 26, a back cap 28,and a handle 30. When fully assembled, the electrode 12 is generallydisposed inside the collet 18, and the collet 18 is generally disposedinside the collet body 16 in a concentric manner as shown. When thecollet 18 is disposed inside the collet body 16, the collet body 16applies an inward force around the collet 18, such that the collet 18tightly grips the electrode 12. In general, electrodes 12 of differentsizes may be used to create different types of welds, and areinterchangeable. Accordingly, each electrode 12 size is generallyaccompanied by a collet 18 and collet body 16 of corresponding sizes.Thus, when the electrode 12 is changed, the collect body 16 and collet18 may be changed as well.

In certain embodiments, the arc starting or welding parameters may beset by sensing the configuration, size, and/or type of the electrode 12itself, the collet 18, the collet body 16, or any combination orrelationship of the above, all of which may include informationindicative of the configuration, size, and/or type of the electrode 12being used. Generally, a sensor 31 may be used to collect this data andcommunicate the data, in the form of a signal, to a material sensing andcontrol system (e.g., the material sensing and control system 78illustrated in FIG. 7) that may be located, for example, within awelding system (e.g., the welding system 76 illustrated in FIG. 6), andis configured to receive such a signal from the sensor 31. For example,in certain embodiments, the sensor 31 may be integrated into the torchbody 22 of the GTAW welding torch 10 such that when the collet body 16is attached to the torch body 22, the sensor 31 may sense informationfrom the collet body 16 (and/or collet 18 and/or electrode 12, etc.)relating to the configuration, size and/or type of the electrode 12. Thesensor 31 and the material sensing and control system 78 may be coupledtogether by a data cable, which conveys the signal from the sensor 31 tothe material sensing and control system 78. For example, in certainembodiments, the data cable may extend through the torch body 22 and thehandle 30, and connect the GTAW welding torch 10 to the material sensingand control system 78.

As described in greater detail below with respect to FIG. 7, thematerial sensing and control system 78 includes control and processingcircuitry configured to receive a plurality of inputs, including asensor signal from the sensor 31. The material sensing and controlsystem 78 may be configured to receive and process various data types,including voltage, image data, frequency, and so forth. The materialsensing and control system 78 may also include volatile or non-volatilememory such as magnetic storage memory, optical storage memory, or acombination thereof. Furthermore, a variety of control parameters,including amperage or frequency of welding output, may be stored in thememory, along with machine readable and executable instructions (e.g.,computer code) configured to provide a specific output relating to suchparameters, given one or more specific inputs. At least one source ofinput may be the sensor signal received by the material sensing andcontrol system 78. Thus, upon receiving the sensor signal, theprocessing circuitry translates the sensor signal into machine readabledata, which becomes an input to the machine executable instructions, andthrough execution of the instructions, the corresponding arc starting orwelding parameters are determined, and the material sensing and controlsystem 78 operates to automatically implement such parametersaccordingly. As such, the material sensing and control system 78 iscapable of automatically determining configuration, size and/or typeinformation relating to the electrode 12, and automatically (e.g.,without user input) select and implement welding parameters for the GTAWwelding torch 10.

The embodiments described herein may include many types of materialsensing systems and methods. FIG. 2A is a detailed view of a collet andcollet body assembly 32 of the GTAW welding torch 10 of FIG. 1, whereinthe collet 18 is disposed inside the collet body 16. As illustrated, thecollet 18 includes a collet end 34, which generally remains outside ofthe collet body 16. Different collets, as used with electrodes 12 ofrespective sizes, may have different lengths. Accordingly, when fullydisposed, a distance d_(collet) between the collet end 34 and the colletbody 16 may vary, and this distance may be indicative of the size (orother parameters, such as a configuration, type, and so forth) of theelectrode 12 used. Thus, in certain embodiments, the GTAW welding torch10 (and associated material sensing and control system 78) may beconfigured to sense the distance d_(collet) between the collet end 34and the collet body 16 as an indicator of the electrode size, and thensubsequently automatically select correct arc starting or weldingparameters. For example, in certain embodiments, the sensor 31 employedmay be an optical sensor configured to optically determine the distanced_(collet) between the collet end 34 and the collet body 16. For furtherexample, the optical sensor may be a low-pixel camera (such as that usedin an optical computer mouse) located inside the GTAW welding torch 10facing the collet end 34 and the respective edge of the collet body 16.The low-pixel camera may send an image of the collet end 34 andrespective edge of the collet body 16 to the material sensing andcontrol system 78, which through image processing is capable ofdetecting the distance d_(collet) between the collet end 34 and thecollet body 16. Thus, the size of the electrode 12 used may be detected.However, as described above, in other embodiments, the distanced_(collet) between the collet end 34 and the collet body 16 may beindicative of other properties related to the electrode 12 being used.For example, particular distances d_(collet) may be mapped to differenttypes of electrodes 12, and the material sensing and control system 78may be configured to translate the distances d_(collet) into themappings (e.g., which may be stored in a memory of the material sensingand control system 78 in, for example, a lookup table) to determine thetype of electrode 12 used.

As another example, FIG. 2B illustrates another collet and collet bodyassembly 32, in which the collet body 16 includes a key piece 36attached on an outward side of the collet body 16. As described above,when the electrode size is changed, the collet body 16 may be changed aswell. Thus, in this embodiment, each different collet body 16 may beassociated with a key piece 36 in a unique position or configurationsuch that each different collet body 16 fits into the GTAW welding torch10 in a unique position within, for example, a corresponding receivingportion such as a groove 37 of the GTAW welding torch 10, allowing thecollet body 16 to be identifiable based on its key piece configurationand/or position. Thus, the GTAW welding torch 10 may be able to detectwhich collet body 16 is being used by the position of the collet body 16and/or by which unique key piece 36 is inserted.

In other words, in certain embodiments, both the distance d_(collet)between the collet body 16 and the collet end 34 of the collet 18 andthe unique key piece 36 that extends from the collet body 16 may be usedto convey information relating to the electrode 12 being used. Forexample, the distance d_(collet) between the collet body 16 and thecollet end 34 of the collet 18 may convey a first piece of information(e.g., the size of the electrode 12) and the unique key piece 36 thatextends from the collet body 16 may convey a second piece of information(e.g., the type of the electrode 12). As another example, specificcombinations of the distance d_(collet) between the collet body 16 andthe collet end 34 of the collet 18 and the unique key piece 36 thatextends from the collet body 16 may, in combination, convey theinformation relating to the electrode 12 being used.

Additionally, in certain embodiments, the different collets 18 may bemarked with different colored markers or LEDs, the different colorscorresponding to the different sizes (or other properties) of therespective electrodes 12. Again, an optical sensor may be configured todetect the color or frequency emitted by the marker or LED on the collet18. An optical type sensor may be configured in other ways to detect thesize of the electrode 12 used. Furthermore, an optical sensor may bealso be employed in welding systems other than GTAW welding systems,and/or in detecting the size of welding materials other than electrodes12.

Furthermore, in certain embodiments, collets 18 may have differentresistance values that may be varied. Thus, the GTAW welding torch 10may be configured to identify the collet 18 used by measuring theresistance of the collet 18. This may be accomplished by coating orforming the collets 18 or collet ends 34 with different materials orthicknesses to vary the resistance of the different collets 18 or colletends 34. As such, contactors inside the GTAW welding torch 10 may beused to measure the resistance of the collet 18 or collet end 34 in theGTAW welding torch 10. Accordingly, the measured resistance value orequivalent voltage may be used by the material sensing and controlsystem 78 to identify the size (or other parameter) of the electrode 12and thus, the appropriate arc starting parameter settings. Again, one ormore of these sensing techniques (e.g., sensing distances, the existenceof unique keys, optical properties, resistance values, and so forth) maybe combined together in certain embodiments.

As previously mentioned, the material sensing techniques describedherein may be used with different welding methods and welding equipment.For example, detecting the size of welding material used, such aswelding wire. In the illustrated embodiment, the GMAW welding torch 38includes a nozzle 40, a contact tip 42, a diffuser 44, an insulator cap46, and a torch body 48. When assembled, a first end 41 of the contacttip 42 is disposed in a receptacle 43 of the diffuser 44, such that thefirst end 41 of the contact tip 42 is securely coupled to the diffuser44. In certain embodiments, the contact tip 42 may be screwed into thereceptacle 43. The nozzle 40 may be generally disposed over the diffuser44 and contact tip 42, leaving a second end 45 of the contact tip 42exposed, the second end 45 being the end opposite the first end 41,which is disposed in the receptacle 43 of the diffuser 44.

FIG. 4 is a cross-sectional view of an assembled GMAW welding torch 38,specifically showing the nozzle 40, the diffuser 44, and the contact tip42. The contact tip 42 further includes a wire channel 50. Generally,welding wire travels from the GMAW welding torch 38, through the wirechannel 50, to the outside of the contact tip 42, where it is consumed.The wire channel 50 of the contact tip 42 is generally configured to fita welding wire of a certain size. Thus, as the welding wire is changedfrom one size to another, the contact tip 42 may be changedrespectively. As such, the size of the welding wire being used isgenerally indicated by the particular contact tip 42 that is used. Incertain embodiments, the GMAW welding torch 38 may sense the identity ofthe contact tip 42 used and set the appropriate arc starting or weldingparameters according to the wire size associated with the particularcontact tip 42 used. Different contact tips 42 may have differentconfigurations. For example, a length l_(contact) of the portion of thecontact tip 42 that is disposed in the receptacle 43 may vary accordingto the size of the welding wire used in the contact tip 42. As such, asensor 49 in the receptacle 43 or diffuser 44 may measure or detect thedisposed length of the contact tip 42. Thus, the identity of the contacttip 42 and welding wire size may be obtained, and correct arc startingand/or welding parameters for such a welding wire size may beimplemented by the material sensing and control system 78.

It should be noted that in some embodiments, the actual welding wiresize may not actually be determined or obtained at any point duringsensing or processing. Such embodiments may detect a certaincharacteristic related to the welding wire size such as theconfiguration of a contact tip 42, collet 18, etc., and directlytranslate the characteristic into the appropriate arc startingparameters, bypassing consideration of the actual wire size. In suchembodiments, the material sensing and control system 78 may store inmemory a reference of preset relationships between such characteristicvalues and the correct arc starting parameters. For example, thematerial sensing and control system 78 may store a reference table inmemory that lists each possible collet length (or associated sensorsignal) and the correct arc starting or welding parameters for eachpossible collet length (or associated sensor signal). Thus, as describedherein, obtaining welding material size may be interpreted as obtaininga representation of welding material size, rather than the directmeasurement itself.

In certain embodiments, the welding system may include an SMAW weldingsystem. FIG. 5 is a side view of an electrode holder 51 to be used withan SMAW welding system. The illustrated electrode holder 51 includes aclamp 52 with teeth 54, and a pivot 56 secured to the clamp 52 such thatthe clamp 52 may open and close at one end. The clamp 52 is generallycoupled to a handle 58 of the electrode holder 51. One side of the clamp52 may be coupled to a lever 60 such that when the lever 60 isdepressed, the clamp 52 is opened. Further, the lever 60 may be coupledto the handle 58 by a spring 62 that exerts an upward pushing force onthe lever 60 such that the clamp 52 has a closing tendency. In general,a consumable electrode is held between the teeth 54 of the clamp 52during welding operation. The thicker the consumable electrode, the moreseparated the clamp teeth 54 will be during welding operation.

Thus, in certain embodiments, the electrode holder 51 may be configuredto sense the size of the consumable electrode. Once the degree ofopenness of the clamp 52 is directly correlated with the size of theconsumable electrode it is holding, the pivot 56 of the clamp 52 may bemechanically coupled to a potentiometer 61 such that the potentiometer61 is turned at a degree proportional to the rotation of the pivot 56.As the rotation of the pivot 56 is directly correlated with the opennessof the clamp 52, which in turn is directly correlated with the size ofthe consumable electrode, the potentiometer 61 output generally reflectsthe size of the consumable electrode. Thus, the size of the consumableelectrode may be detected, and appropriate arc starting or weldingparameters may be automatically determined and implemented.

Additionally, in certain embodiments, the size of the consumableelectrode held between the teeth 54 of the clamp 52 may be detected bymeasuring the distance between the lever 60 and the handle 58, as theposition of the lever 60 is generally proportional to the distancebetween the teeth 54 of the clamp 52. In such an embodiment, the lever60 may include a linear contactor 59 extending from the lever 60,through the inside of the spring 62, and through a hole in the handle58. At corresponding positions inside the handle 58 are a plurality ofreceiving contactors arranged linearly in the direction of the linearcontactor 59. Thus, as the lever 60 is depressed, the linear contactor59 lowers further through the spring 62 and makes contact with one ormore receiving contactors. The receiving contactors are arranged suchthat as the linear contactor 59 is further lowered through the spring62, more or different receiving contactors become electrically coupledto the linear contactor 59. Thus, with appropriate circuitry, theposition of the lever 60, and thus the size of the consumable electrode,may be detected. Additionally, in certain embodiments, the electrodeholder 51 (and other welding torches) may employ a strain gauge inobtaining a representation of welding material size.

The disclosed material sensing techniques are capable of sensing thesize (or other parameter) of welding material used in a welding process,either directly by sensing the welding material itself or indirectly bysensing the configuration of a welding consumable such as the collet 18,collet body 16, contact tip 42, clamp 52, and so forth. In certainembodiments, the parameters of the welding material may be sensedcontinuously, and the arc starting parameters may be changed when achange in the sensed material parameter occurs. In other embodiments,the parameters of the welding material may be sensed only one time permaterial change. For example, parameters of the welding material mayonly be sensed upon the insertion of a collet 18 (in a GTAW weldingtorch), as the insertion of a collet 18 may signify a change in weldingmaterial size, for example. Further, in certain embodiments, insertionof the collet 18 may depress a trigger, which sends a signal to thematerial sensing and control system 78 to collect data from the sensor.

FIG. 6 illustrates a method 63 that may be employed to sense the weldingmaterial size (or other property of the welding material) andautomatically implement appropriate arc starting parameters, inaccordance with an embodiment of the present invention. The method 63includes the steps of activating the material sensing and control system78 (block 64) and receiving one or more sensor signals from a sensorrelating to the size of the welding material used (block 65). Activatingthe material sensing and control system 78 (block 64) may includeturning the entire welding system 76 on such that the material sensingand control system 78 is activated when the welding system 76 isactivated. In certain embodiments, activating the material sensing andcontrol system 78 (block 64) may occur when a trigger of the weldingtorch is triggered, signifying that welding material is being changed.Such embodiments may include sensing when a portion of the welding torchtorch is opened or closed, removed or inserted, such actions beingnecessary for changing welding material. For example, in certainembodiments, a button or switch disposed inside the welding torch may bedepressed when a collet 18, contact tip 42, etc., is inserted into thewelding torch.

Next, a sensor signal (block 66) is outputted from the sensor and actsas an input to the material sensing and control system 78. The sensorsignal (block 66) may include a variety of signal types, such as imagedata, voltage, frequency, and so forth. The sensor signal (block 66) isthen processed by the material sensing and control system 78 (block 68).This step may include converting the raw sensor signal into computerusable data compatible with the material sensing and control system 78.For example, the material sensing and control system 78 may store apredetermined list of possible sensor signal values and the set of arcstarting and/or welding parameters that correspond to each sensorsignal. The material sensing and control system 78 further translatesthe sensor signal into a set of arc starting and/or welding parameters(block 70) by matching the received sensor signal to one of thepredetermined sensor signals, and thus the correct parameters. Incertain embodiments, the predetermined sensor signals may be organizedas discrete values or be divided into ranges. As such, the receivedsensor signal may also be discrete and match a predetermined sensorsignal exactly, or it may be an analog value that may fall into one ofthe predetermined sensor signal ranges.

As the sensor signal is matched to the correct arc starting parameters,a set of arc starting commands (block 72) is outputted. For example, ifa sensor signal having a voltage within a first range is received, afirst arc starting or operational command may be produced, and if asensor signal having a voltage within a second range is received, asecond arc starting or operational command may be produced. The arcstarting command (block 72) may then be the input used to implement theappropriate arc starting or welding parameters for the welding system76, which correspond to the received sensor signal (block 74). Accordingto the presently disclosed method 63, the correct arc starting orwelding parameters are automatically implemented according to the size(or other property) of the welding material used, without the need foroperator intervention.

The system for implementing the method 63 of FIG. 6 is depicted in FIG.7, which illustrates an exemplary welding system 76 that includes amaterial sensing and control system 78. The welding system 76, such as awelder, may be coupled to a welding torch 80. The welding system 76and/or the material sensing and control system 78 may further include aprocessor 82 which receives inputs such as sensor data from the weldingtorch 80 via a communication cable 86. The processor 82 may also sendcontrol commands to the welding output portion of the welding system 76in order to implement the correct welding parameters. Further, theprocessor 82 is generally coupled to a memory 84, which may include oneor more software modules 88 that contain executable instructions,transient data, input/output correlation data, and so forth. Generally,the processor 82 receives sensor data from the welding torch 80,references data stored in the memory 84 to find the welding parametersthat correspond to the received sensor data, and implements theparameters. As previously mentioned, the welding system 76 may also becoupled to a gas source 90, which may provide shielding gas to thewelding system 76. As such, a gas valve 92 may be included in thewelding 76 and configured to be controlled by the material sensing andcontrol system 78, as gas flow may be considered an arc starting orwelding parameter in certain embodiments.

It should be noted that, in other embodiments, the abovementionedprocesses may or may not all occur in the material sensing and controlsystem 78. For instance, there may be one or more controllers orprocessors that control different aspects of the welding system 76. Incertain embodiments, a first system receives the sensor signal and isdistinct from, but coupled to, a second system that processes the sensorsignal, which may also be distinct from, but coupled to, a third systemthat implements the arc starting or welding parameters. Alternatively,the same system may receive and process the sensor signal, while anothersystem implements the arc starting and/or welding parameters.

As illustrated in FIG. 7, the material sensing and control system 78 maybe provided as an integral part of the welding system 76 in someembodiments. That is, the material sensing and control system 78 may beintegrated into the welding system 76, for example, during manufacturingof the welding system 76. Such a welding system 76 may also includeappropriate computer code programmed into the software to support thematerial sensing and control system 78. However, in other embodiments,the material sensing and control system 78 may be provided as a retrofitkit that may enable existing welding systems 76 with the materialsensing and control capabilities described herein. To that end, suchretrofit kits may be configured as add-ons that may be installed ontoexisting welding systems 76, providing material sensing and controlcapabilities. Further, as the retrofit kits may be installed on existingwelding systems 76, they may also be configured to be removable onceinstalled. Additionally, both the integrated and the retrofit systemsmay be configured for wired or wireless communication between thematerial sensing unit and one or more controllers of the welding system76.

Further, in certain embodiments, the gas source 90 may be configured tosupply shielding gases, such as argon, helium, carbon dioxide, and soforth, to the welding torch 80 for use in the welding operation. In suchembodiments, the gas may enter the gas valve 92 located in the weldingsystem 76. The gas valve 92 may be configured to communicate with thematerial sensing and control system 78, such that the material sensingand control system 78 may also control the flow of gas to the weldingtorch 80. As such, the welding system 76 may also be configured toautomatically change and/or set gas flow parameters based on the weldingmaterial that is sensed by the material sensing and control system 78.In a sense, gas flow parameters may also be considered an arc startingand/or welding parameter.

As described above, the presently disclosed welding system 76 may employnumerous technical methods of detecting an indication of the size ofwelding material used in a welding process. Examples of such methodsinclude optical methods, mechanical methods, electrical methods (e.g.,resistance, voltage, etc.), and so forth. Likewise, many differentcontrol schemes, hardware components, and software components may beconfigured in a variety of ways to provide the correct arc startingparameters based on the welding material used.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A welding system, comprising: a welding torch; a welder coupled tothe welding torch configured to produce a welding arc in the weldingtorch; and a sensor configured to sense a parameter indicative of a sizeof a welding material used by the welding torch, wherein the sensor isconfigured to send a signal to the welder, the signal representing theparameter indicative of the size of the welding material, wherein thewelder is configured to automatically implement at least one of a arcstarting parameter or a welding parameter based on the signal.
 2. Thewelding system of claim 1, wherein the sensor senses the parameterindicative of the size of the welding material by measuring the size ofthe welding material directly.
 3. The welding system of claim 1, whereinthe sensor senses the parameter indicative of the size of the weldingmaterial by detecting a configuration of a welding consumable of thewelding torch, wherein the configuration of the welding consumable isindicative of the size of the welding material.
 5. The welding system ofclaim 1, wherein the sensor is disposed within the welding torch.
 6. Thewelding system of claim 1, wherein the welder comprises computerreadable code configured to receive the signal as an input, and outputexecutable instructions for implementing the appropriate arc startingparameter, welding parameter, or both, in the welder.
 7. The weldingsystem of claim 1, wherein the welding torch comprises an electrodeholder, wherein the electrode holder is configured to hold the weldingmaterial, and wherein the sensor is configured to sense the size of thewelding material held in the electrode holder.
 8. The welding system ofclaim 1, wherein the welding torch comprises a collet body having amechanical key feature, wherein the sensor senses a location of themechanical key feature within a corresponding receiving portion of thewelding torch, and wherein the location of the mechanical key featurewithin the receiving portion is indicative of the size of the weldingmaterial.
 9. The welding system of claim 1, wherein welding torchcomprises an electrode holder having a clamp that clamps onto thewelding material, wherein the sensor senses a degree of opening of theclamp, and wherein the degree of opening of the clamp is indicative ofthe size of the welding material.
 10. A welding system, comprising: awelding torch comprising a sensor configured to sense a parameterindicative of a size of a welding material used by the welding torch andto output a signal representative of the sensed parameter; and acontroller disposed within a welder, wherein the controller isconfigured to receive the signal from the sensor, to convert the signalinto a corresponding set of arc starting parameters, welding parameters,or both, and to implement the arc starting parameters, weldingparameters, or both.
 11. The welding system of claim 10, wherein thesensor senses the parameter indicative of the size of the weldingmaterial by measuring the size of the welding material directly.
 12. Thewelding system of claim 10, wherein the sensor senses the parameterindicative of the size of the welding material by detecting aconfiguration of a component of the welding torch, wherein theconfiguration of the component is indicative of the size of the weldingmaterial.
 13. The welding system of claim 10, wherein the sensor and thecontroller are configured to be separable from the welder and thewelding torch.
 14. The welding system of claim 10, wherein thecontroller comprises a memory that stores a predefined set of possiblesignal values and the arc starting parameters or welding parameters tobe implemented in response to each the possible signal values.
 15. Thewelding system of claim 10, wherein the controller is integrated intothe welder.
 16. The welding system of claim 10, wherein communicationbetween the sensor and the controller is wireless.
 17. A method,comprising: determining a sensor signal using a sensor associated with awelding torch, wherein the sensor signal is indicative of a size of awelding material used by the welding torch; communicating the sensorsignal from the sensor to a controller disposed within a welder;processing the sensor signal by translating the sensor signal into acorresponding set of arc starting parameters, welding parameters, orboth; and implementing the corresponding set of arc starting parametersor welding parameters in the welder, wherein the welder is configured toproduce an arc with the corresponding set of arc starting parameters,welding parameters, or both.
 18. The method of claim 17, comprisingdetecting that the welding material has been changed in the weldingtorch.
 19. The method of claim 17, comprising wirelessly transmittingthe sensor signal from the sensor to the controller.
 20. The method ofclaim 17, wherein the sensor is disposed within the welding torch or anelectrode holder associated with the welding torch.